Aerated Concrete Products Optimum Structure For Hot Regions _ Thermally Insulant Blocks _ Thermally Insulant Roof Tiles . _ Hordi Blocks . _ Steel Reinforced Precast Units .SIPOR€X 1. INTRODUCTION Siporex is lightweight Autoclaved Aerated Concrete (AAC) manufactured from the same components as conventional concrete: cement, sand and water in addition to aluminum powder and other additives. The product is available as blocks with different dimensions and precast reinforced units, i.e., wall panels, lintels and floor/roof slabs forming a complete building system. A villa of one or two storeys can easily be constructed using Siporex blocks, floor and roof slabs, and lintels without the need of reinforced concrete main frame. Industrial production of this versatile building material was started in 1929 and it has been produced and used for building construction ever since. First in Europe and now world-wide. Here in the Kingdom of Saudi Arabia, LCC Siporex Company was established in 1977 and has been producing Siporex AAC material at our plant in the Second Industrial Estate, AlKhar| Road. With our continued expansion of additional manufacturing plant to sustain the growing demand, Our current total production capacity has intensified to about 360,000 cubic meters of Siporex AAC products per year. Siporex manufacturing plant in Riyadh, Saudi ArabiaSIPOR€X [RAC BUILDING SYSTEM 2. CODES & STANDARDS Various international codes and standards had been developed to provide engineers and designers with provisions for the analysis and design of AAC factory-produced blocks and reinforced panels based on various research studies and experiences on its use. These include guidelines or recommended practice addressing the materials, manufacture and structural design of AAC including design considerations such as erection and construction details incorporating the use of AAC products in conventional construction. Some of these Codes & Standards are listed below: | CODE OR | DESIGNATION STANDARD — NO. DEFCRIPTICE Guide for Low Density Precast Concrete Floor, ACl | 401 523:2R | Root and Wail Units : nee €1555.03A | Standard Practice for Autoclaved Aerated Concrete | Masonry —_—_ “| _ Standart pecification for Precast Autoclaved cole 1386-98 | Aerated Concrete Wall Construction Units DEUTCH | DIN 4165 | Autoclaved Aerated Concrete Blocks NORM BRITISH | BS 8110 — Part STANDARD | 2. Section Six Autoclaved Asratey Soncrate BRITISH BS EN 771- STANDARD | 4.2001 Autoclaved Aerated Concrete Masonry Units BRITISH BS EN Determination of the Dry Density of Autoclaved STANDARD 678:1994 Aerated Concrete _ BRITISH BS EN Determination of the compressive Strength of STANDARD 679 :1994 Autoclaved Aerated Concrete BRITISH BS EN Determination of the Drying Shrinkage of STANDARD | 680: 1994 _| Autoclaved Aerated Concrete | BRITISH BS EN STANDARD | 772-10.1999 | Method of test for Masonry Units BRITISH BS EN Determination of Moisture Content of Autoclaved STANDARD 1353:1997 Aerated Concrete SASO SASO 1579 _/ Precast Autoclaved Aerated Concrete SWEDISH BUILDING CODE | autoclaved Aerated Concrete Products Design Procedure for Siporex Roof, Floor, Wall FA ae cetera Panels, Masonry Blocks and Lintels of Autoclaved eee Lightweight Cellular Concrete(Report # NER-297) RILEM Autoclaved Aerated ConcreteSIPOReX ‘RAC BUILDING SYSTEM 3. MANUFACTURING Siporex is produced by a highly complex and advanced manufacturing process in our factory under the careful contro! of chemists and engineers. Siporex is made either as steel reinforced panels using moulds 6 meters jong, 1.5 meters wide and 600 mm deep or as non-reinforced blocks using moulds 6 meters tong, 1.5 (or 1.2) meters wide and 600 mm deep. The basic raw materials are sand, water, aluminum powder and cement. The sand is ground to required fineness in a ball mill before mixing with other raw materials with water to form slurry to which a trace of aluminum powder is added as expanding agent. Regulated amount of aluminum powder gives accurate control of density of the final product. Moulds are only partly filled with slurry which then expands in a controlled reaction to fill the moulds. When the mass is sufficiently hard, the moulds are stripped and the cake is wire-cut to close tolerances into blocks using high-precision cutting technology. These are then steam cured under high pressure in autoclaves for up to 15 hours. This completes the chemical process, resulting in @ unique crystal structure of calcium silicate hydrate and ensuring a stable and inert product giving AAC outstanding qualities not found in other products. After cooling to ambient temperature, the batches are demoulded, and stacked for further handling and storage. The block stacks are strapped, marked and stored on wooden pallets. Each pallet can be stored with up to 3 bundles of blocks (180 om high). At the storage area, the floor should be level to avoid tilting of stocks. The manufacturing of Aerated Lightweight Concrete as blocks by. LCC Siporex implements and maintains a Quality Management System which fulfills the requirements of ISO 9001:2000. , For final products, compressive test, shrinkage and _ dry densities are carried out on a daily basis. The -.. finished goods inspection program ensures the "products quality. The material is now ready for “1 Toading and deliverySIPORE€X ‘BAC BUILDING SYSTEM 4. PROPERTIES & BENEFITS OF USING SIPOREX The manufacturing process as well as the basic ingredients used provide Siporex its unique properties and benefits not found in other traditional building materials and will radically change the construction practices in this industry. Lightweight Sipotex products are supplied with nominal dry density of 550 kgim* and weigh less than @ quarter compared to conventional concrete. Other densities such as 450 or 600 kg/m’ can also be produced upon request. Due to the lightweight property of Sipotex, foundation loads are greatly reduced resulting to big savings in the overall cost. Its light weight also means significant advantage in ‘transportation cost. Strength In relation to its dry density, Siporex can withstand relatively high compressive stress, which in the aspect of application is very sufficient to take building loads. Siporex achieves its full strength during autoclaving process. Minimum compressive strength is about 35 kg/cm” for nominal dry density of 550 kgim’* Resistance to Fire Siporex has remarkable fire resistance properties and is non- combustible, Heat migration takes Place at a slow rate due to its low thermal conductivity, giving Siporex excellent fire resistance. A 15 cm thick panel will resist fire for seven life-saving hours. Siporex is ideal for firewall application and as protection for structural steel construction. Non-toxic Siporex itself is_ ecologically harmless, since it neither contains gases nor fibers, it is neither dangerous to ground-water nor does it releases any radioactive radiation No pollutants or toxic by-products are produced in the manufacturing process or even when subjected to fire. Energy Efficient Siporex ensure comfortable room temperature without the need for additional insulation. Its thermal insulation and heat retention offer a ‘good protection against rapid cooling or heating up too much. This means lower power consumption in environmental management system. With a thermal conductivity (°K value) of 0.144 Wim°C, it is the only structural materials classified by SCECO as insulating material Workability Siporex products can be sawn, cut, slot, drilled, chased and nailed with ordinary woodworking tools which makes them easier to install than other building materials. This also simplifies the installation of electro- mechanical services and other utiities, which means more cost savings. Acoustic Insulation Siporex meets the appropriate standards for sound insulation in house building, which means quieter and more comfortable interior. In industrial construction, Siporex minimizes industrial noise pollution. The sound absorption of untreated Siporex surface is better than that of dense concrete. A 20 cm_ thick Siporex wall with 3mm surface finish will have STC rating of about 48 dB. Durability Siporex products do not contain any organic matter subject {0 deterioration and wil not degrade even under severe _ weather conditions. Structures built. several decades ago are sill in active use today.SIPORe€X ‘BRC BUILDING SYSTEM 5. PRODUCT DATA 5.1 Product Application & Characteristic Data Siporex solid blocks are used as load-bearing and non load-bearing walls and as thermally insulating roof tiles in addition to being used as Hordi blocks or infils for ribbed slabs. The production process guarantees the accurate dimensions with slim tolerance of #3mm for thickness & width and +5mm for length. This allows for a straight and plumbed walls resulting in less on-site trimmings and reduces the quantity of mortar and finishing materials required, 5.2 Masonry Blocks Dimensions For the past decades, LCC Siporex had been supplying AAC blocks with a standard face size of 25 om high x 60 cm long only in various thicknesses. However, due to the increasing demand and growing popularity of the use of AAC blocks, LCC Siporex have started the production of new dimensions of blocks in line with the continued expansion of additional manufacturing plant to sustain the market requirements. Siporex blocks are now produced at the following standard sizes: Standard face size: 25 om high x 60 cm long: Standard face size: 20 om high x 60 cm long: 5.3 Hordi Blocks Hordi blocks or infill blocks for ribbed slabs can be produced in various dimensions to form lightweight infill between in-situ reinforced concrete ribs designed to span in one or both directions. Due to their excellent bondage to in-situ concrete, Siporex Hordi blocks are easily arranged to form permanent part of the slab, providing excellent thermal insulation as well as fire resistance material. Hordi blocks are produced with density of 450 kgim’ according to the following dimensions: Length : 60cm Width 2 37/38 om or 40 cm Thickness = 20, 25, 30, 35 om Other sizes may be produced upon request only. Hordi blocks are not available in stock and are manufactured against order only. Hordi blocks application 5.4 Thermal Insulating Tiles Roof insulation of existing conventional roof can still be improved with the use of Siporex thermal insulating tiles available at the following dimensions: 60 x 60 x 7.5 cm 60x 25x7.5 60 x 25 x 5 cm Other dimensions can be produced upon request. 5.5 Box Type Lintels (LB) Box type lintels are designed with special steel reinforcement arrangement produced with depth equal to the height of Siporex blocks for ease of construction. This eliminates shuttering and cast- in-situ works as well as avoids thermal bridges caused by the use of traditional concrete lintels.5. PRODUCT DATA SIPORe€X ‘BAC BUILOING SYSTEM 5.6 Maximum Clear Span of Box Type Lintels with Various Design Loads (Height = 25 cm) 100 200m 150 500 kg/m 350 om 1000 kg/m 150cm 250cm 1500 kg/m 75cm — 2000m 5.7 Packing Data for Siporex Blocks Siporex blocks are delivered ready for use and packed in easily transportable wooden pallets. The pallets should be unloaded at the site by construction-site cranes, forklifts or other suitable hoisting equipments. For ease in unloading of materials, it is suggested to order Siporex blocks in whole bundle or pallet volume to avoid handling loose quantities. Following table is an easy reference in making order of some standard sizes of Siporex blocks in bundles or pallets. Thickness of Box Type Lintel (mm) 200 $ : per t lc Landi Loa Bundle | _ Pallet 7 | No. of No. of ] No. of No. of | . . nail | | Blocks | Bundle | m°per —— m° per Block Dimensions | Blocks | Blocks | pe Samar. | (eaeee | [10x 25 x 60 om 66.66 15x 25x600m | 44.44 20x 25 x 60 cm 33.33 | 25% 25 x 60 om 26.66 30 x25 x 60 cm 22.22 10x 20x 60 cm [15% 20x 600m 20 x 20 x 60 cm 30x 20x 60 om 40x 20 x 60 om_ SIPOREX ROO! 5x25x60em | [667 150 7.5 x 25 x 60 cm | 6.67 100 7.5 x 60 x 60 cm l 2.78 40 "OREX HORDI BLOCKS: 20 x 37/38 x 60 om 22.22 44 21 3 0.945 | 2.835 20x 40 x 60. cm 20.83 | 4.17 18 3 0.864 2.592 25 x 37/38 x 60 cm 17.78 44 18 3 1.013 3.038, 30 x 37/38 x 60 cm 14.8 4.4 15 L 3 1.013 3.038 30 x 40 x 60 om 13.89, air | 42 | 3 25 35x 37/38 x 60 om 127 44 12 3 12.835SIPOR€X ‘RAC BUILDING SYSTEM 6. INSTALLATION / PLASTERING 6.1 Block Laying The first course should be laid on cement-mortar bed of thickness about 1 to 3 cm depending on the evenness of the base and should maintain a correct level for fast installation progress in the following courses. It is recommended to spray the mortar face of the block before installation to keep damp at erection time especially during the hot seasons. Alter installation, spray with water twice a day for 3 consecutive days for curing of the mortar. Three types of Mortars can be applied on the succeeding courses: 6.1.1) Siporex Glue (for thin joints): Pre-mixed mortar ~ only water is to be added. Thickness of glue should not exceed 3 mm in horizontal and vertical joints in order to achieve the ideal consumption rate as follows: #7 kg/m2 for Siporex blocks 25 cm thick ‘+ 6 kg/m? for Siporex blocks 20 cm thick ‘+ 5 kg/m? for Siporex blocks 15 cm thick 6.1.2) Ordinary Mortar with Gesol 1:6 Cement : Sand respectively in addition to water (with 10% of Gesol). The erection can be carried out normally as for conventional blocks. (Gesol is a liquid material used as bonding agent and retardant for the mortar especially during hot weather. Gesol is available at Siporex factory in 3 kg and 25 kg plastic containers). 6.1.3) Ordinary Mortar with Lime: 4:1:10 Cement : Lime : Sand 6.2 Plastering of Siporex Block Wall Before plastering, dirt and loose particles should be removed from walls. Spray walls with water and follow one of the two methods mentioned below: a 6.2.1) Traditional Plasterin, Simian to plastering of conventional block walls with the following mix ae * Splattering (8mm): Use 1 cement : 3 sand mixed with : solution of water and Gesol (20% of the volume). Spray with water twice a day. * Ordinary Plastering Mortar: (1 ~ 1.5 em thick, apply 24 hours after the splattering) Use 1 cement : 6 sand mixed with solution of water and Gesol (10% of volume). 6.2.2) Plastering with Pre-mixed Mortar (Serpo Prime) Water is added to the pre-mixed plaster supplied in bags of 25 and 50 kgs. Surfaces should be thoroughly cleaned and wetted without any splattering. Apply plaster directly with a thickness ranging between 0.5 to 1 cm, In both above methods, walls should be watered twice a day after plastering for three consecutive days. 76. FIXINGS / CONNECTIONS 6.1. Bolts and Fixings SIPOReX AC BUILDING SYSTEM ‘Special types of fixings can be used with Siporex structures such as galvanized cut nails, bolt fastenings and wall plugs. The type of anchoring method to be used depends on the holding capacity required. These types of fixings are used in installation of doors and windows, as well as wall accessories with weights not exceeding the allowable loads of the type of fixing used, Ordinary wire nails should not be used since their anchoring ability to Siporex is low. Through-bolts should be used in case of heavy fixtures such as water heater and hanging lavatories. Some of the types of fixings and anchors suitable for use with Siporex AAC materials are as follows: Galvanized Cut Nails Galvanized Cut Nails different lengihs and are available at our Sipores Factory. Cul nails are hammered divecthy into Siporex walls and do not need to be pre-crilled They can be used to fasten light to moderate weight items fo Sipores. ariNoU anon ToREaUWALONT STEEL a Hilti HGN Anchors HGN Gas Conerete Anchors, ‘manufactured by Hilti Company is Cadmium-free Polyamide anchor specially suitable for AAC concrete base. Available Ii various sizes, it provides high pressure per unit of Seen Fischer Anchors Also available with plastic plugs suitable for light 10 mediun weight fixings in aerated concrete. It has fins providing grip as well as resistance 10 rotation. This type is also available in various sizes 10 suit the particular needs 6.3 Connection with dissimilar material$ SIPOR€X ‘AC BULDING SYSTEM 7. SIPOREX BUILDINGS8. LIST OF SOME PROJECTS SIPOR€X ‘ARC BUILDING SYSTEM Client / Contractor | Name of Project Location Year | 1. Saudi Petrochemical Co. 136 Housing Units. Jubail 1987 2. AK. Group Aziziyah Housing 208 Villas AlKhobar 1992 3. ABV Rock Group SSSP Residential Cmpd 120 Units Madinah 4992 4 ABV Rock Group SSSP Residential Cmpd 110 Units Abha_ 1993, 5.__| ABV Rook Group. ‘SSSP Residential Cmpd 110 Units. Buraidah 71993 6__| Kimma Construction ‘Yanpet Housing Project 200 Villas ‘Yanbu 7993 Ze ABV Rock Group ABV Compound Jeddah 1993 8. A. K. Group. Tabuk Gardens Village — 60 villas Tabuk, 4994 3. | Sata Engineering — Blocks Taiwan 7894 10__| Saudi Real Estate Co, D.0. Housing Project Riyadh 1994 11__| MS. AlSuwaidi Cont. Est Yanpet Housing Proj. Ph. 00 Vilas_| Yanbu 994 42._| AMERAB-ECO- Tawam 89 Villas & B. Walls AbuDhabi_ 1995, 43._| AlMobti for Trad. & Cont. 273 Villas Compound Djibouti, 1996 74. [| AK. Group RSLLF. Housing Tabuk 1996. 15._| international Center Co. YCC — 40 Villas Yanbu_ 1997 416._ | CCC (ARAMCO) Residential & Industrial Compound Shaybah_ 1997, 17._| Gen. Presidency for Girls Educ. _| 16 Colleges: Buildings Diff. sites 1997 18.__| AlSwayeh Co. Hyatt Regency Hotel Riyadh 1996 19._| Developed Building Co. Landmark Shopping Malll Proj. Qatar 41999 20. REDICO Tabuk Gardens Village — 2A, Tabuk 2000, 21._| Developed Bidg Co. Al ittinad & Al Rayyan Stadiums (Qatar 2001 22._| Saudi Wiemer & Tracte Al Rushaid Village 2 Alkhobar 2001 23. _| Saudi Binladin Group King Abdullah Multi-storey Hotel Madinah 2001 24. Nasser Al Hajri Yanpet Housing Proj.-Ph.3 Yanbu. 2002 25._| Modern Villas Real Estate Housing Compound Riyadh 2002, 26. Al Someie Real Estate Housing Compound Riyadh 2002. 27._| Abdulla Allssa Group Alissa Compound Riyadh 2003 28._| Al Marasem Cont. Residential Compound Shouaiba 2005: 29. | Bin Jarallah Group Gizan Housing Jizan 2003 30._| Al Marasem Cont. Housing Compound Tufail 2003 31._| AlMashrab Co. ‘Abha University ‘Abha. 2004 '32._[ AlAli Engineering 108 Villas Qatar 2004 33 AIAli Engineering Villaggio atar 2004 34. | King Abdullah Foundation 2,500 vilas ~ Dev. Housing Project Diftsites | 2004-2006 35. | EMECO. ‘Al Amar Gold Mine — Housing ‘Quayyiah 2004 36___| Al Ali Engineering 30 Villas Qatar 2005 37__| ALAli Engineering 84 Villas (Qatar 2008 '36._| Assad Said Corporation "ASC Housing Compound ‘Jubail 72006. 39,_| Al Ma’awdah Const. 25 Villas Bahrain 2006 40._| Saudi Binladin Group ‘Al Haram Shopping Center Madinah 2007 43.__| ALAli Engineering ‘The Pearl Qatar ‘Qatar 2007 42 [ ALAli Engineering 58 Vilas Qatar 2007 43.__| Makkah Co. Supply of Blocks Kuwait/iraq 2007 44__[ Al Mabda Rezayat Housing Compound ‘Jubail 2007 45__| Saudi Binladin Group Dar Al-Qibla Complex Madinah 2007, 46_| Sinoma Hofuf Cement Factor Hofuf 2007 47._| AbMarasem Co. Chany Housing — Diff. sites_| 2007 48_| Al-Othman Agri Prod Housing Compound Hotuf 2008) 49. | Danash Co. Al Jouf Cement Factory — Housing Turaif_ 2008 50. SMA, Proj. & Devt Co. Khartoum College of Med, Science Sudan 2008; 10Head Office : Riyadh SMe Eee eal eed Khubar Tel. +966 3 889 5751 - Fax +966 3 889 35 96 Jeddah Tel. +966 2 645 3051 - Fax +966 2 645 49 31 [email protected] www.iccsiporex.com